JLG 45HA Parts Manual (3120626)PDF – Download En

Description

JLG 45HA Parts Manual (3120626)PDF – Download En

TABLE OF CONTENTS:

JLG 45HA Parts Manual (3120626)PDF – Download En

SECTION 1 – FRAME ……………………………………………………………………………………………………………………………………………………… 9
FIGURE 1-1. FRAME AND STEERING INSTALLATION – 5FT-9IN/1.75M 2WD FRAME (WITH SINGLE ROD CYLINDER) ……. 10
FIGURE 1-2. FRAME AND STEERING INSTALLATION – 6FT-6IN/2M 2WD FRAME (WITH DOUBLE ROD CYLINDER) ………. 14
FIGURE 1-3. FRAME AND STEERING INSTALLATION 6FT-6IN/2M 4WD FRAME …………………………………………………………… 18
FIGURE 1-4. TIRE AND WHEEL DRIVE INSTALLATIONS …………………………………………………………………………………………….. 22
FIGURE 1-5. DRIVE HUB ASSEMBLIES ……………………………………………………………………………………………………………………… 28
FIGURE 1-6. DRIVE HUB/BRAKE ASSEMBLIES ………………………………………………………………………………………………………….. 34
FIGURE 1-7. DRIVE BRAKE ASSEMBLY – AUSCO ………………………………………………………………………………………………………. 40
FIGURE 1-8. DRIVE BRAKE ASSEMBLY – MICO …………………………………………………………………………………………………………. 42
FIGURE 1-9. DRIVE MOTOR ASSEMBLY – 2WD …………………………………………………………………………………………………………. 46
FIGURE 1-10. DRIVE MOTOR ASSEMBLY – 4WD ……………………………………………………………………………………………………….. 50
FIGURE 1-11. VALVES INSTALLATION (FRAME MOUNTED) ……………………………………………………………………………………….. 54
FIGURE 1-12. LOCKOUT VALVE ASSEMBLY ……………………………………………………………………………………………………………… 58
FIGURE 1-13. TOW PACKAGE INSTALLATION …………………………………………………………………………………………………………… 60
SECTION 2 – TURNTABLE ……………………………………………………………………………………………………………………………………………. 63
FIGURE 2-1. CONTROL VALVES INSTALLATIONS – STEPPER VALVES ………………………………………………………………………. 64
FIGURE 2-2. CONTROL VALVES INSTALLATIONS – VICKERS (KOHLER GAS AND ELECTRIC MACHINES) …………………… 68
FIGURE 2-3. CONTROL VALVES INSTALLATIONS – VICKERS (FORD GAS, DEUTZ DIESEL AND KUBOTA DIESEL) ………. 72
FIGURE 2-4. STEP CONTROL VALVE ASSEMBLY ……………………………………………………………………………………………………… 76
FIGURE 2-5. VALVE ASSEMBLY – FPS (STEER) …………………………………………………………………………………………………………. 78
FIGURE 2-6. VALVE ASSEMBLY – 4 STACK BANG-BANG ……………………………………………………………………………………………. 80
FIGURE 2-7. VALVE ASSEMBLY – FPS ………………………………………………………………………………………………………………………. 84
FIGURE 2-8. CONTROL VALVE ASSEMBLY (VICKERS) (PRIOR TO OCTOBER 1994) …………………………………………………… 86
FIGURE 2-9. CONTROL VALVE ASSEMBLY – (VICKERS) (OCTOBER 1994 TO PRESENT) …………………………………………….. 90
FIGURE 2-10. VALVE ASSEMBLY – SINGLE STACK BANG-BANG………………………………………………………………………………… 94
FIGURE 2-11. ACCESSORY VALVE ASSEMBLY (MILLER) ………………………………………………………………………………………….. 96
FIGURE 2-12. ACCESSORY VALVE ASSEMBLY (HYDRAFORCE) ……………………………………………………………………………….. 98
FIGURE 2-13. TURNTABLE, BEARING AND SWING DRIVE INSTALLATION ………………………………………………………………… 100
FIGURE 2-14. SWING BRAKE ASSEMBLY ……………………………………………………………………………………………………………….. 104
FIGURE 2-15. SWING MOTOR ASSEMBLY ………………………………………………………………………………………………………………. 106
FIGURE 2-16. FORD ENGINE INSTALLATION – WITH ELECTRONIC IGNITION (PRIOR TO MARCH 1990) …………………….. 108
FIGURE 2-17. FORD ENGINE INSTALLATION – WITH DISTRIBUTORLESS IGNITION SYSTEM (MARCH 1990 TO PRESENT)
……………………………………………………………………………………………………………………………………………………………………………… 114
FIGURE 2-18. DUAL FUEL INSTALLATION (FORD ELECTRONIC IGNITION – PRIOR TO MARCH 1990) ………………………… 122
FIGURE 2-19. DUAL FUEL INSTALLATION (FORD DISTRIBUTORLESS IGNITION – MARCH 1990 TO PRESENT) ………….. 124
FIGURE 2-20. GENERATOR INSTALLATION – 110V (FORD) (OPTIONAL) …………………………………………………………………… 126
FIGURE 2-21. DEUTZ ENGINE INSTALLATION …………………………………………………………………………………………………………. 130
FIGURE 2-22. GENERATOR INSTALLATION 110 VOLT (DEUTZ) (OPTIONAL) …………………………………………………………….. 136
FIGURE 2-23. PUMP ASSEMBLY – BARNES (FORD AND DEUTZ POWERED MACHINES) …………………………………………… 140
FIGURE 2-24. KUBOTA ENGINE INSTALLATION ………………………………………………………………………………………………………. 142
FIGURE 2-25. THROTTLE AND FUEL SHUT-OFF INSTALLATION (KUBOTA) ………………………………………………………………. 148
FIGURE 2-26. KOHLER ENGINE INSTALLATIONS …………………………………………………………………………………………………….. 150
FIGURE 2-27. DUAL FUEL INSTALLATION – KOHLER ……………………………………………………………………………………………….. 154
FIGURE 2-28. GENERATOR INSTALLATION (KOHLER) (OPTIONAL) …………………………………………………………………………. 156
FIGURE 2-29. ELECTRIC POWERED MACHINES COMPONENTS INSTALLATION ………………………………………………………. 158
FIGURE 2-30. PUMP ASSEMBLY – BARNES (KOHLER, KUBOTA AND ELECTRIC POWERED MACHINES) …………………… 162
FIGURE 2-31. BATTERY CHARGER ASSEMBLY (ELECTRIC POWERED MACHINE) …………………………………………………… 164
FIGURE 2-32. DOUBLE BATTERY PACKAGE AND INVERTER INSTALLATIONS (ELECTRIC MACHINE OPTIONS) ………… 166
FIGURE 2-33. TANKS INSTALLATION ………………………………………………………………………………………………………………………. 168
FIGURE 2-34. ROTARY OIL COUPLING INSTALLATION ……………………………………………………………………………………………. 174
FIGURE 2-35. OPTIONAL MANUAL DESCENT INSTALLATION ………………………………………………………………………………….. 176
FIGURE 2-36. GROUND CONTROL BOX INSTALLATION (MACHINES WITH ELECTRIC BOOM LIMIT SWITCHES BUILT
PRIOR TO MAY 1988) …………………………………………………………………………………………………………………………………………….. 178
FIGURE 2-37. GROUND CONTROL BOX INSTALLATON (GAS/DIESEL MACHINES WITH HYDRAULIC BOOM LIMIT
SWITCHES BUILT MAY 1988 TO MARCH 1990 AND ELECTRIC MACHINES WITH HYDRAULIC BOOM LIMIT SWITCHES
BUILT MAY 1988 TO PRESENT) ………………………………………………………………………………………………………………………………. 182
FIGURE 2-38. GROUND CONTROL BOX INSTALLATION (GAS/DIESEL MACHINES WITH HYDRAULIC BOOM LIMIT
SWITCHES BUILT MARCH 1990 TO PRESENT)………………………………………………………………………………………………………… 186
FIGURE 2-39. TILT INDICATOR, LIGHTS AND ALARMS INSTALLATIONS (TURNTABLE MOUNTED) ……………………………. 190
FIGURE 2-40. HOODS INSTALLATION (GAS/DIESEL MACHINES BUILT PRIOR TO MARCH 1990 AND ALL ELECTRIC
MACHINES) …………………………………………………………………………………………………………………………………………………………… 194
FIGURE 2-41. HOODS INSTALLATION (GAS/DIESEL MACHINES BUILT MARCH 1990 THROUGH 1992) ………………………. 198
FIGURE 2-42. HOODS INSTALLATION (GAS/DIESEL MACHINES BUILT 1993 TO PRESENT) ………………………………………. 200
TABLE OF CONTENTS
6 45HA 3120626
SECTION 3 – BOOM ……………………………………………………………………………………………………………………………………………………. 203
FIGURE 3-1. BOOMS AND LIMIT SWITCHES INSTALLATIONS …………………………………………………………………………………… 204
FIGURE 3-2. MAIN BOOM ASSEMBLY ……………………………………………………………………………………………………………………… 208
FIGURE 3-3. TOWER BOOM ASSEMBLIES ……………………………………………………………………………………………………………….. 212
FIGURE 3-4. BOOM WIPERS INSTALLATION ……………………………………………………………………………………………………………. 216
SECTION 4 – PLATFORM ……………………………………………………………………………………………………………………………………………. 219
FIGURE 4-1. STANDARD PLATFORM AND FOOTSWITCH INSTALLATION …………………………………………………………………. 220
FIGURE 4-2. LOW MOUNT PLATFORM AND FOOTSWITCH INSTALLATIONS …………………………………………………………….. 226
FIGURE 4-3. FIBERGLASS PLATFORM INSTALLATION …………………………………………………………………………………………….. 230
FIGURE 4-4. ROTATOR MOTOR ASSEMBLY ……………………………………………………………………………………………………………. 232
FIGURE 4-5. CONSOLE BOX ASSEMBLY – PQ CONTROLLERS AND STEPPER VALVES …………………………………………….. 234
FIGURE 4-6. CONSOLE BOX ASSEMBLY – PQ CONTROLLERS AND VICKERS VALVES ……………………………………………… 238
FIGURE 4-7. CONSOLE BOX ASSEMBLY – PQ CONTROLLERS AND VICKERS VALVE ……………………………………………….. 242
FIGURE 4-8. CONSOLE BOX ASSEMBLY – OEM CONTROLS AND VICKERS VALVE (MACHINES BUILT PRIOR TO
OCTOBER 1990) …………………………………………………………………………………………………………………………………………………….. 246
FIGURE 4-9. CONSOLE BOX ASSEMBLY – OEM CONTROLLERS AND VICKERS VALVE (MACHINES BUILT OCTOBER 1990
TO PRESENT) ………………………………………………………………………………………………………………………………………………………… 250
FIGURE 4-10. OPTIONAL COMMON PLATFORM MOUNTED COMPONENTS ………………………………………………………………. 254
SECTION 5 – CYLINDER ……………………………………………………………………………………………………………………………………………… 259
FIGURE 5-1. ACCUMULATOR ASSEMBLY (MACHINES WITH STEPPER VALVES) ………………………………………………………. 260
FIGURE 5-2. AXLE LOCKOUT CYLINDER ASSEMBLY ……………………………………………………………………………………………….. 262
FIGURE 5-3. LEVEL CYLINDER ASSEMBLY (TOWER BOOM) ……………………………………………………………………………………. 264
FIGURE 5-4. LIFT CYLINDER ASSEMBLY (MAIN BOOM) ……………………………………………………………………………………………. 266
FIGURE 5-5. LIFT CYLINDER ASSEMBLY (TOWER BOOM) ……………………………………………………………………………………….. 268
FIGURE 5-6. PLATFORM LEVEL CYLINDER ASSEMBLY (MAIN BOOM) (PRIOR TO OCTOBER 1992) …………………………… 270
FIGURE 5-7. PLATFORM LEVEL CYLINDER ASSEMBLY (MAIN BOOM) (OCTOBER 1992 TO PRESENT) ………………………. 272
FIGURE 5-8. STEER CYLINDER ASSEMBLY (2WD – DOUBLE ACTING ROD) ………………………………………………………………. 274
FIGURE 5-9. STEER CYLINDER ASSEMBLY (2WD SINGLE ACTING ROD) …………………………………………………………………. 276
FIGURE 5-10. STEER CYLINDER ASSEMBLY (4WD) …………………………………………………………………………………………………. 278
FIGURE 5-11. TELESCOPE CYLINDER ASSEMBLY (MAIN BOOM) (PRIOR TO JUNE 1991) ………………………………………….. 280
FIGURE 5-12. TELESCOPE CYLINDER ASSEMBLY – MAIN BOOM (JUNE 1991 TO PRESENT) …………………………………….. 282
FIGURE 5-13. TELESCOPE CYLINDER ASSEMBLY (TOWER BOOM) (JULY 1988 TO PRESENT) …………………………………. 284
FIGURE 5-14. CYLINDER BELLOWS INSTALLATION (OPTIONAL) ……………………………………………………………………………… 286
SECTION 6 – HYDRAULIC …………………………………………………………………………………………………………………………………………… 289
FIGURE 6-1. HYDRAULIC DIAGRAM – AXLE LOCKOUT ……………………………………………………………………………………………… 290
FIGURE 6-2. DRIVE HYDRAULIC DIAGRAM (2WD WITH SWIVEL AND WITH VICKERS VALVES) …………………………………. 292
FIGURE 6-3. DRIVE HYDRAULIC DIAGRAM (4WD WITH SWIVEL AND WITH VICKERS VALVES) …………………………………. 296
FIGURE 6-4. LIFT AND LEVEL (TOWER BOOM) HYDRAULIC DIAGRAM (VICKERS VALVES AND HYDRAULIC BOOM LIMIT
SWITCHES) ……………………………………………………………………………………………………………………………………………………………. 300
FIGURE 6-5. LIFT AND SLAVE (MAIN BOOM) HYDRAULIC DIAGRAM …………………………………………………………………………. 302
FIGURE 6-6. PUMP HYDRAULIC DIAGRAM (VICKERS VALVES – FORD GAS AND DEUTZ DIESEL MACHINES) ……………. 304
FIGURE 6-7. PUMP HYDRAULIC DIAGRAM (VICKERS VALVES – ELECTRIC MACHINES) ……………………………………………. 308
FIGURE 6-8. ROTATION HYDRAULIC DIAGRAM ……………………………………………………………………………………………………….. 312
FIGURE 6-9. STEER WITH SWIVEL HYDRAULIC DIAGRAM ……………………………………………………………………………………….. 314
FIGURE 6-10. SWING HYDRAULIC DIAGRAM (WITH VICKERS VALVES) ……………………………………………………………………. 316
FIGURE 6-11. TELESCOPE (MAIN BOOM) HYDRAULIC DIAGRAM……………………………………………………………………………… 318
FIGURE 6-12. TELESCOPE (TOWER BOOM) HYDRAULIC DIAGRAM (FORD GAS AND DEUTZ DIESEL) ………………………. 320
FIGURE 6-13. TELESCOPE (TOWER BOOM) HYDRAULIC DIAGRAM (ELECTRIC MACHINES) …………………………………….. 322
FIGURE 6-14. HYDRAULIC DIAGRAM LIST ……………………………………………………………………………………………………………….. 324
SECTION 7 – ELECTRICAL ………………………………………………………………………………………………………………………………………….. 327
FIGURE 7-1. ELECTRICAL DIAGRAM LIST ……………………………………………………………………………………………………………….. 328
FIGURE 7-2. ACCESSORY VALVE WIRING DIAGRAM ……………………………………………………………………………………………….. 334
FIGURE 7-3. CONTACTOR BOX WIRING DIAGRAM (ELECTRIC MACHINES) ……………………………………………………………… 336
FIGURE 7-4. DUEL FUEL WIRING DIAGRAM (FORD MACHINES OPTION) ………………………………………………………………….. 338
FIGURE 7-5. GENERATOR WIRING DIAGRAM (DEUTZ MACHINES OPTION) ……………………………………………………………… 340
FIGURE 7-6. GENERATOR WIRING DIAGRAM (FORD MACHINES OPTION) ……………………………………………………………….. 342
FIGURE 7-7. PLATFORM WIRING DIAGRAM (GAS AND DIESEL MACHINES) ……………………………………………………………… 344
FIGURE 7-8. PLATFORM WIRING DIAGRAM (ELECTRIC MACHINES) ………………………………………………………………………… 346
TABLE OF CONTENTS
3120626 45HA 7
FIGURE 7-9. STANDARD WIRING DIAGRAM (DEUTZ DIESEL MACHINES)…………………………………………………………………. 348
FIGURE 7-10. STANDARD WIRING DIAGRAM (FORD GAS MACHINES) …………………………………………………………………….. 350
FIGURE 7-11. STANDARD WIRING DIAGRAM (ELECTRIC MACHINES) ……………………………………………………………………… 352
SECTION 8 – DECALS ………………………………………………………………………………………………………………………………………………… 353
FIGURE 8-1. DECALS INSTALLATIONS (45HA PRIOR TO AUGUST 1991) ………………………………………………………………….. 354
FIGURE 8-2. DECALS INSTALLATIONS (45HA AUGUST 1991 TO PRESENT) ……………………………………………………………… 358
SECTION 9 – RECOMMENDED SERVICE PARTS STOCK …………………………………………………………………………………………….. 363
FIGURE 9-1. MODELS 45HA GAS AND DIESEL MACHINES WITH VICKERS VALVES STANDARD PARTS ……………………. 364
FIGURE 9-2. MODELS 45HA GAS AND DIESEL MACHINES WITH VICKERS VALVES VARIABLE PARTS ……………………… 366
SECTION 10 – SPECIAL OPTIONS ………………………………………………………………………………………………………………………………. 367
FIGURE 10-1. SPECIAL OPTIONS LIST ……………………………………………………………………………………………………………………. 368
FIGURE 10-2. U/L MACHINES SPECIAL OPTIONS ……………………………………………………………………………………………………. 372
FIGURE 10-3. 440V ELECTRIC PEDESTAL MACHINE SPECIAL OPTIONS ………………………………………………………………….. 374
FIGURE 10-4. JAPANESE MACHINE OPTIONS …………………………………………………………………………………………………………. 376
PART NUMBER INDEX ………………………………………………………………………………………………………………………………………………. 377

IMAGES PREVIEW OF THE MANUAL:

PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

S.M